Restraining dense packaging system for LCD glass sheets

ABSTRACT

A reusable dense packaging system used to transport large size display substrates, is provided made up of three main components; a pallet frame, a cover, and restraining means. The restraining means securely hold the glass sheets within the cover and on the pallet frame. Restraining means includes one or more retaining bars moving towards and away from the front of the glass sheets and a mechanical system. The mechanical system may include the use of a pressing panel, a belt apparatus, a scissor-like mechanism, positioning devices, or a retaining bar pulling system, each capable of moving towards and away from the front of the glass sheets. Each embodiment allows for packaging from 1 to N glass sheets with flexibility and stability and with manual or automatic operation.

BACKGROUND OF THE INVENTION

1. FIELD OF THE INVENTION

The present invention relates generally to packaging, and particularlyto packaging for large size display substrates, such as a stack of glasssheets.

2. TECHNICAL BACKGROUND

In recent years, glass substrates for Liquid Crystal Display (LCD)panels have increased in size, along with enlargement of Liquid CrystalDisplay panel sizes.

Conventional non-contact packaging, such as PP-case and L-supporter, hasdominated the market as the delivery model for smaller size glasssubstrates, such as Gen 4, 730 mm×920 mm, or smaller. Recognizinglimitations in packing density, their requirements for significantstorage space, and the difficulty to extend their application toever-increasing sizes, these conventional non-contact or spacer typepackages have effectively reached a practical limitation for glass sizesgreater than or equal to Generation 5.

Pursuant to the trend for larger and larger substrates sizes for LiquidCrystal Display comes the need for suitable packaging for the transferof large glass sheets to and from the Glass manufacturers to the Displaymanufacturers or in essence, but not limited to, the providers of ThinFilm Transistor panels and/or the Color Filter panels.

In some prior art approaches, when glass sheets are transported, forexample, to a Liquid Crystal Display manufacturing plant, to a Thin FilmTransistor (TFT) manufacturer or to a Color Filter (CF) maker, the glasssheets are typically placed in a crate or a square box with removableside panels at a glass sheet manufacturing plant typically withprotective plastic films or other separating materials being disposed oneither side of each glass sheet before transportation. When containersof these types are used, however, the size of glass sheets to betransported is limited. Further, these containers, though adequateenough in delivery, is poor in mechanical strength. For these reasons,in the prior art, high density safe transportation of large glass sheetscould be improved. In addition, the glass sheets are undesirablysusceptible to contamination during transportation, since the crates orboxes are also poor in weatherability, often requiring over-pack (e.g. abox within a box). In the Liquid Crystal Panel manufacturing plant, thedelivered glass sheets are manufactured into substrates for liquidcrystal panels, after uncrating the glass sheets, removing theprotective films or separating materials disposed on either side of eachglass sheet, and cleaning the glass sheets. Further, there is a problemin that a cleaning process for removing adherents, such as a residualadhesive remaining on the glass sheet after removing the adhesiveprotective films and contaminants which are attached on the glass sheetsin the course of the transportation, typically takes a long time. Itshould be noted that even some non-adhesive materials, such aspolyethylene or polymeric films, if used, may leave some residualorganic materials which must also be washed off with a detergent orother like wash; however, these non-adhesive residuals are typically notas difficult to clean off or as time consuming as residuals left behindby adhesives.

Prior art approaches for performing the above described desiredcapabilities that are known in the art include, but are not limited to,the following examples.

Prior art Japanese Patent Application Number P2000-142856A, entitledGlass-Plate Storage Method, filed on Nov. 13, 1998 by Nippon ElectricGlass Co. Ltd. and published on May 23, 2000 provides a glass-platestorage method for high storage efficiency for storing a plurality ofglass plates is obtained through interposing interleaving papers in thespaces between, and essentially separating the glass-plate surfaces,thereby reducing the degree of contamination and marring of theglass-plate surface.

Also in the prior art, Japanese Patent Application No. 2000-203679,entitled Glass Panel Storage Method, filed on Nov. 12, 1999 by NipponElectric Glass Co. Ltd. provides a glass panel storage method with whicheven when glass panels are used as the substrate material for flatdisplay panels to be stored, separating members are interposed only atthe surface edges of the glass panels. Thus, there is no contaminationof the effective surface and storage efficiency is achieved.

Also in the prior art, U.S. Pat. No. 6,527,120 entitled “Containers forPackaging Glass Substrates”, granted on Mar. 4, 2003 provides packagingfor flexible LCD substrates where the containers include arc-shapedgrooves which apply an elastic strain to the substrates reducing damageto the substrates during transport.

However, these and other existing prior art solutions still have severallimitations. Firstly, there is limited protection of container contentsfrom weather during transportation. Though these prior art containers ingeneral are likely proven adequate for effectively meetingtransportation testing specifications, the container coverings can“pool” with liquid and the container must be wrapped in plastic orcovered over with other means in order to seal it from elements.Additionally, the disposing of these consumable items becomes anenvironmental and cost issue as well. Secondly, there is marginalmechanical strength of the container due to side-wall construction ofcorrugated plastic materials.

Where tilting is not required (for instance as in typical PP or L typeprior art containers), loading glass sheets is complex due to precisionof placement in slots. This type of vertical orientation of glass sheetswhen the container is in the “normal” or upright position also requiresadditional equipment to tilt the container for loading and unloading.Additionally, prior art PP or L type containers typically only holdabout 20 sheets of glass requiring frequent change-out of containers.Further, the construction of mild steel with painted surfaces found alsoin the prior art is susceptible to chipping, flaking and particlegeneration, as well as corrosion, resulting in marginal clean roomcompatibility. Construction is also subject to deformation during normalwarehouse handling.

In certain other prior art solutions, there is difficulty in handlingcontainers on conveyors and truck beds due to limited contact area of apallet base. Additionally, glass cushioning materials exhibitsignificant deformation over time, requiring periodic adjustment ofpacking and unloading robot controls, as well as periodic fullreplacement due to permanent deformation. Still further, in certainprior art solutions, there is an inability to scale up for larger sizesof glass without material handling equipment (overhead lift) beinginvolved. This would require two or more operators to handle assemblyand disassembly. Still further, most of the prior art solutions, includemultiple loose parts (some on the order of 10 or more pieces plushardware) which though allow for collapsibility, are costly both toassemble and to maintain. One primary limitation of the prior art isthat there is marginal retention of glass movement in container. Theprior art methods to secure a stack of glass sheets and to avoidmovement during transportation after it has been packed or shipped arenot sufficient to retain the glass sheets from moving under allconditions such as transportation conditions of excessive vibration orshock; hence there is the potential for breakage to occur.

As becomes evident, the larger the glass sheets become, the fewer sheetscan be packaged into a container. Thereby existing methods of packagingLCD glass seem to have met practical limitations in scaling beyond Gen 5glass sheet size [approximately 1100 mm×1300 mm]. They carry an inherentpenalty in space and logistics due to low sheet counts per containervolume.

This stipulates the need for denser packaging, utilizing one or morelayer of surface protection between glass sheets. For instance, thearchitectural and automotive glass industries have realized this needand have begun to use densely packed vertical boxes and tilted L-framesto ship glass substrate product. “Dense packs” are emerging as thefuture delivery model for Gen 5 glass sheet sizes as it is known in theart and larger, where Gen 5 can be supported by both the conventionalpackaging and dense packaging. Dense packaging has been proven as aviable delivery model, however, as substrate sizes become even larger,such as with Gen 7 and beyond, new challenges arise for dense packaging,particularly around size and weight of the container components, whichbecome even more unwieldy for operators to handle, as well astransportation constraint issues, for instance, transporting containersthrough standard size doors, available sizes of shipping containers andstandard trucks.

A new approach is needed that preferably overcomes the disadvantages ofany of the prior art solutions above while still providing safe, highdensity and cost-effective transportation of large glass sheets andreduced time necessary for glass sheet cleaning process aftertransportation.

A new approach is also needed to address the difficulties arising fromthe ever increasing glass sheet and container size and the need formaking such a container alternatively ‘automation compatible’ in boththe LCD glass manufacturer's packaging operation as well as in the glassuser's unpacking operation.

A new approach is needed that leverages features of a manual orautomation compatible packaging system towards allowing for a fullyautomated container system when desired.

SUMMARY OF THE INVENTION

One aspect of the present invention includes a container for packagingand transporting one or more glass sheets where the container includes aframe having a pallet with a base, a cover secured to the pallet suchthat said one or more glass sheets is sealably covered therewith, asupport panel and seat provided with cushioning members, and restrainingmeans for controllably and adjustably retaining said one or more glasssheets with respect to the support panel of the pallet.

In one aspect of the invention is the restraining means further includesone or more retaining bars moving towards and away from the front of theone or more glass sheets and a mechanical system for moving said one ormore retaining bars. In another aspect of the invention, the restrainingmeans is preferably integrated into said cover. Further aspects of therestraining means include a pressing panel coupled with the retainingbars.

In another aspect of the invention, the mechanical system includes aplurality of belts and belt restraint devices. In still other aspects ofthe invention, restraining means further includes at least onescissor-like mechanical system coupled to the one or more retaining barsor a plurality of mechanical positioning devices coupled to the one ormore retaining bars. In still another aspect of the invention, themechanical system is integrated with the frame and includes a retainingbar pulling system. The inventive aspects of the restraining means canbe operated manually or automatically. In another aspect of theinvention, the cover is sealably affixed to the frame via a gasket seal.

In a further aspect of the invention, pressing panel is removable. In ayet further aspect of the invention, the retaining bars operateindependently from each other. Still further aspects of the inventionare that the frame and cover are made of a metal or other compositematerial.

In another aspect of the invention, the one or more glass sheets arestacked with no spacing in between. In a still further aspect of theinvention, non-scratching interleaf materials are positioned between theglass sheets. In an additional aspect of the invention the interleafmaterials further include non-adhesive plastic films attached on eitherside of each glass sheet and a paper sheet is disposed between each ofthe adjacent plastic films.

Additional features and advantages of the invention will be set forth inthe detailed description which follows, and in part will be readilyapparent to those skilled in the art from that description or recognizedby practicing the invention as described herein, including the detaileddescription which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description present embodiments of the invention,and are intended to provide an overview or framework for understandingthe nature and character of the invention as it is claimed. Theaccompanying drawings are included to provide a further understanding ofthe invention, and are incorporated into and constitute a part of thisspecification. The drawings illustrate various embodiments of theinvention and together with the description serve to explain theprinciples and operations of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is further illustrated with reference to the followingdrawings in which:

FIG. 1 is a perspective view of the entire container configurationthereof in accordance with a preferred embodiment of the invention.

FIG. 2 is a side view of the container shown in FIG. 1.

FIG. 3 is a rear view of the container shown in FIG. 1.

FIG. 4 is a side view of the container shown in FIG. 1, with a coverthereof being removed.

FIG. 5 is a front view of the container shown in FIG. 1, with the coverthereof being removed.

FIG. 6 is a schematic cross-sectional view of a glass sheet stack inaccordance with a preferred embodiment of the present invention.

FIG. 7 is a front view of a container with a restraint system integratedinto the cover in accordance with a still further alternate preferredembodiment of the invention.

FIG. 8 is a back view of the configuration shown in FIG. 7 showing thecontainer cover having an internal scissor restraint system.

FIG. 9 is a top view of the configuration in FIGS. 7 and 8 showing theunexpanded internal scissor restraint system.

FIG. 10 is a top view of the configuration in FIGS. 7 and 8 showing theexpanded internal scissor restraint system.

FIG. 11 is a front view of the container with a retaining bar integratedinto the cover in accordance with a still further preferred embodimentof the invention.

FIG. 12 is a side view of the configuration in FIG. 11.

FIG. 13 is a rear view of the configuration in FIG. 11.

FIG. 14 is a rear view of the container with a retaining bar integratedinto the cover in accordance with a still yet further preferredembodiment of the invention.

FIG. 15 is a side view of the configuration in FIG. 14.

FIG. 16 is a side view of the configuration in FIG. 14 showing apreferred retraction mechanism.

FIG. 17 is an inside view of the configuration in FIG. 14 showingpreferred attachment points.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention restraining packaging system overcomes prior artproblems with a high-density packing system wherein glass can be easilypackaged by a manufacturing company and unloaded with ease by customerswhile also reducing container space requirements by a factor of 10×-20×for an equivalent quantity of glass, as well as improving overalllogistics due to the reduced numbers of containers required for anequivalent number of glass sheets. The invention also provides forcontrollable and repeatable retention of the glass suitable for amultiplicity of transportation environments.

As will be shown, dense packing of the LCD substrates allowssubstantially more glass to be packaged in a given container, requiringless container packages, and hence, less storage space for thosepackages. For example the typical spacing for prior art L-supporters isapproximately 20 mm for a Gen 5 substrate (one container typically beingcapable of holding about 20 sheets of glass). Comparatively, a densepack has substantially no spacing with only the thickness of the twolayers of film and paper between the glass sheets, these thicknessestypically being less than 200 microns (0.2 mm).

Reference will now be made in detail to the present preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Wherever possible, the same reference numberswill be used throughout the drawings to refer to the same or like parts.

FIGS. 1 to 5 show the general configuration of a container according toa first preferred embodiment of the present invention. FIG. 1 is aperspective view of the preferred container with the cover on; FIG. 2 isa side view; FIG. 3 is a rear view of the container. FIG. 4 is a sideview of the container with a cover thereof being removed, and FIG. 5 isa front view of the container shown in FIG. 4.

Referring now to FIGS. 1 to 5, in accordance with a preferred embodimentof the present invention, a container which is designated generallythroughout this specification by the reference numeral 100 includes apallet 110 (preferably metal) which can be loaded on and lifted by aforklift truck, and a cover 130 preferably made of a laminated aluminumpolymer composite, a metal, a high strength polymer or a metal/polymerlaminate or other composite material to be positioned over a stack ofglass sheets 120 supported on the pallet 110 such that a seal isproduced in the container (see description infra with respect to FIG.5). The container preferably has no paint on it and as such, is notsusceptible to flaking or chipping.

In accordance with a preferred embodiment of the invention, theweatherproof cover 130, which sealingly covers the glass sheet stack 120from the front thereof, is preferably constructed from an aluminumframe, such as square tubing or extrusions, and an aluminum compositepanel, and formed in the shape of box that is open backward and downwardusing a front panel 131 which may include one or more sections, a toppanel 132, and side panels 133 a, 133 b (133 a shown). A plurality ofhandles 134 is provided on the front panel 131 and a handle 135, such asa grip recess or recessed handle, is provided on each of the side panels133 a, 133 b. The edges of the cover 130 are disposed in intimatecontact with the corresponding portions of the pallet 110 and supportpanel 112 via a gasket seal 112 a. The cover 130 is releasably mountedon the pallet 110 with a simple operation by means of clamping members136, which are provided, preferably two on each side of the supportpanel 112, in a manner spaced along the rear edges of the side plates133 a, 133 b and the opposite ends of the support panel 112. The cover130 preferably includes four wheels (not shown) at its bottom corners,one for each corner, such that mounting and dismounting of the cover 130to and from a pallet 110 is facilitated. The wheels can either beinternal or external to the cover 130.

The pallet 110, which is preferably made of a stainless steel material,includes a substantially flat bottom base allowing for highly-flexibleconveyance by conveyors employing rollers, chains, walking-beams, orlike methods and including entry slots 111 a which can receive a fork ofa forklift truck from the front (shown) or from the rear or from any ofthe sides (not shown); a support panel 112, inclined backward about 18degrees or more as shown in FIG. 4 and secured on the pallet 110; abottom glass support seat 113 which is secured on the pallet 110; and acover sealing gasket 112 a which is adhesively attached around theperimeter of the support panel 112 and the pallet 110 and cover support111 as shown in FIG. 4.

The container 100 provides many advantages such that the container isrobust and durable for long-term use, and the container can be returned,cleaned and reused repeatedly.

FIG. 2 shows a side view of the container 100 of FIG. 1 with the cover130 placed on the container in accordance with the preferred embodimentof the present invention. The side view of the container allows us toview additional structural elements. For instance, four posts 115 areprovided (one shown in FIG. 2 and also shown in FIGS. 1 and 4) so as toextend between the support panel 112 and the pallet 110, whereby thesupport panel 112 is securely held on the pallet 110 while maintainingan inclined position. Alternative equally effective embodiments mayinclude a different number of posts 115 in any number of differentconfigurations as a matter of design choice by one of skill in the art.Additionally, a belt take-up type restraining device 151 is shown whichwill be discussed in detail infra with respect to FIGS. 4 and 5.

FIG. 3 is a rear view of the container shown in FIG. 1 in accordancewith the preferred embodiment of the present invention showing theconfiguration of the four posts 115 that extend between frame 114 of thesupport panel 112 and the cover support 111. Four clamping members 136are also shown in this view. Additionally, two restraining belt devices151 are depicted in the rear view at the top part of the cover and willbe discussed in further detail below.

Referring now to FIG. 4, a side view of the container of the preferredembodiment of the present invention is shown with the cover 130 thereofremoved to include cushioning members 116, preferably made of EPDMrubber (a resilient elastomer based on ethylene-propylene-dieneterpolymer) preferably with a hardness of about 60 on the Shore scale ofhardness, are adhered on the support panel 112 and the seat 113 by meansof a suitable adhesive. It should be noted that other forms ofcushioning members, other hardnesses, other equally effective ways tocushion with or without the use of an adhesive, either using otherpolymer-like materials that exhibit similar properties or using foam ora laminated foam for instance are also further contemplated byalternative design embodiments to this invention. In a preferredembodiment, the glass sheet stack 120 is placed on the surface of theseat 113 via the cushioning member 116 and held in an inclined positionby the pressing panel 440.

As can be seen from FIGS. 4 and 5, a removable pressing panel 440preferably made of light weight aluminum and having thereon thecushioning member 116 is in contact with the front surface of the glasssheet stack 120 which is disposed in an inclined position on the seat113 of the pallet 110 and the support panel 112.

A pair of leg standoffs 442 a, 442 b, for supporting the pressing panel440 on the seat 113, is provided on the lower edge of a frame 441 (seeFIG. 5) fixed around and on the front side of the pressing panel 440.Handles 443 a, 443 b (handle 443 a is shown in FIG. 4 and both handlesshown in FIG. 5) are also provided on the frame 441. Vertical posts 460protect the glass sheets from breaking when removing the cover.Different sizes of glass sheets within a given Generation family areaccommodated in container 100. Pressing panel 440 preferably includesframe 441, leg standoffs 442 a, 442 b, handles 443 a, 443 b, andvertical posts 460.

The pressing panel 440 is restrained relative to the support panel 112preferably by means of two belts 450 a and 450 b. More specifically, thebelts 450 a, 450 b are attached to the lower part of the support panel112, one on each side of the support panel 112. They then extend alongthe lower side surface of the glass sheet stack 120, one on each side,in the frontward direction toward the pressing panel 440, extending pastthe pressing panel 440 from the back side (the glass sheet stack 120side) to the front side thereof, and then extending upwardly along thefront surface of the pressing panel 440. Subsequently, the belts 450 a,450 b again wrap around to the back side of the pressing panel 440 andextend toward the support panel 112 along the upper side surface of theglass sheet stack 120, one on each side, in the backward directiontoward the support panel 112. Finally, the belts 450 a, 450 b arereleasably engaged on the back side of the support panel 112, forexample, preferably with winch-type belt take-up and tightening devices(belt restraining devices) 151 a, 151 b (151 b shown in FIG. 4) whichenable the adjustment of the tightness of the belts. These restrainingdevices provide adjustable and controllable means for retaining theglass sheets relative to the support panel of the pallet or acontrollable tension over the glass sheets and the ability to tightenthe restraint as needed. The belts are preferably made of a highstrength polymer strap material, such as polyester, nylon, or the like.A different number of belts and restraint devices may be desireddepending on design effectiveness and choice.

The pressing panel 440 is easily removed from the glass stack 120 byreleasing the belts 450 a, 450 b from the winch-type tightening devices151 a, 151 b in order to permit access to the glass.

FIG. 5 depicts other elements previously described of the front view ofthe container 100 with the cover 130 thereof removed and the pressingpanel 440 in position.

In the cross-sectional view of the glass stack 120 depicted in FIG. 6,an preferred embodiment of the present invention shows, but is not belimited to, the use of non-scratching interleaf materials positionedbetween the glass sheets, such as papers or hybrids of paper or polymer,non-adhesive or even adhesive types of materials.

It should be noted that FIG. 6 is depicted as having a verticalorientation only for the convenience of illustration purposes astypically the glass stack 120 is inclined when placed in container 100.

Accordingly, in the preferred embodiment, the glass sheet stack 120herein is shown to include a plurality of glass substrate or glasssheets 621, which are arranged such that a surface of each glass sheetis parallel to that of the glass sheet adjacent thereto; non-adhesiveplastic films 622, which are attached on either side or between thesheets to act as a protective interleaving material for preserving thepristine surface and for controlling moisture exposure of each glasssheet 621; and paper sheets 623, each of which is disposed between eachtwo adjacent plastic films 622. As can be seen from FIG. 6, the upperedges of the paper sheets 623 project beyond the upper edge of the glasssheet 621, and this facilitates removal of the paper sheets 623 aftertransportation and before the manufacturing process. The upper edge ofthe films 622 may or may not project beyond the upper edge of the glasssheet 621 depending upon preference.

One implementation of the preferred embodiment is preferably constructedwith dimensions of width 1600 mm by height 1600 mm by depth 970 mm. Thecontainer 100 is enabled to accommodate up to 500 glass sheets 621having dimensions extending to 1200 mm by 1300 mm with the long side ofthe sheet extending horizontally.

The present invention packaging system can be adapted easily toaccommodate increases in glass size and container size.

From the foregoing description, in the container 100 of the presentembodiment, the glass sheet stack 120 is disposed on the rigid metalpallet 110, fixed in position by the pressing panel 440 and furthersealingly covered with metal cover 130, so that safe, high-densitytransportation of large glass sheets 621, which hitherto had not beenachievable, is enabled, resulting in significant reductions intransportation cost per glass sheet 621.

In the preferred embodiment, the glass sheet stack 120 is transported ina sealed state, substantially reducing the risk of glass sheets 621becoming contaminated during normal transportation. This, combined withthe use of the non-adhesive protective films 622 attached on either sideof the glass sheet 621, contributes to significant reduction of the timerequired for the cleaning process prior to use of the glass sheet 621.

Furthermore, the glass sheet stack 120 is held in the container 100 inan inclined position, so that the glass sheet stack 120 is kept stableand the introduction and extraction of the glass sheet stack 120 to andfrom the container is facilitated.

In accordance with a preferred aspect of the present invention and asmentioned supra, embodiments include entry slots 111 a, for receiving afork of a forklift truck, provided in the metal pallet 110, so that thecontainer 100 containing therein the glass sheet stack 120 whichcontains substrates 621, paper sheets 623 and films 622, can be easilytransported within a warehouse or storage facility and easily loadedonto a delivery vehicle or the like.

In accordance with the preferred embodiment of the present invention,each of the cushioning members 116 is provided on the support panel 112and the seat 113 and the pressing panel 116 (as shown in FIG. 4), sothat there is no risk of damaging the glass substrates 621, andabsorbing vibrations which may occur during transportation.

Further, the pressing panel 440, disposed in contact with the frontsurface of the glass sheet stack 120, is restrained relative to thesupport panel 112 of the pallet 110 by means of the two belts 450 a, 450b, so that there is no possibility that the glass sheet stack 120 movesduring transportation. In addition, the belt restraining devices 151aand 151 b are provided, so that the container can flexibly accommodatevariations in the quantity and size of the glass sheets 621 (as well asvariation in the thickness of the glass sheet stack 120) and permitcontrol over the retaining force applied to the surface of the glass.

Referring now to FIGS. 7-10, in accordance with yet another preferredembodiment of the present invention, a container 700 is shown to includesome additional features beyond those depicted in FIGS. 1 to 6. Theseadditional features pertain to an alternate glass restraint systemprimarily including a cover 710 with an integrated automated scissorrestraint system 720. It should be noted that the many of the structuralelements found in FIGS. 1 to 6 can be carried over to FIGS. 7 to 10 suchas for instance, the general frame design, the mechanical principles ofthe restraint system, and the fundamental materials of constructiondescribed supra. It should be noted that certain features such as thebelts and pressing panel have been eliminated from this alternateembodiment.

Additionally, it should be noted that in FIGS. 7 to 10, container cover710, is depicted as transparent to better illustrate the integratedinternal restraint system though preferably, it is made of the samematerials as discussed above in conjunction with containers described inFIGS. 1 to 6. Transparent covers, however, may be desirable to one ofskill in the art for providing visibility into the cavity of thecontainer and are fully contemplated for use in the instant invention asit would assist those utilizing the container in viewing how many glasssheets are packaged into a container.

FIG. 7 shows cover 710 in a final resting position where the cover 710is fully covering the glass support area with the glass sheets inside.

A retainer system 720 designed into cover 710 as shown in FIGS. 7 to 10,such that an integral cover/glass retention type container 700, isprovided to facilitate automation, flexibility and stability. Theintegrated automated scissor restraint system 720 has one primaryfeature, namely integrated scissors, which will be discussed in moredetail below. Cover 710 may include lifting attachments, not shown, tofacilitate installation and removal of the cover.

Structural features of restraint system 720 that are designed into thecover 710 are shown in more detail in FIG. 8 which is a rear perspectiveview of the container 700. Referring to FIG. 8, the novel features insystem 720 preferably include restraint scissors 810, restraint bars815, clamping members 820 (similar to clamping member 136 describedsupra) to latch/unlatch the cover, locking mechanism (not shown) to holdthe restraint bars in position following application of a specifiedamount of glass restraint force. When unlocked, the restraint bars 815may be retracted from the glass allowing removal of the cover.

The restraint system 720 preferably incorporates a light-weightscissor-like mechanism 810, which provides a wide range of motion, yetis simple in its approach. Scissor mechanism 810 is preferably made ofaluminum tubing or extrusion. The restraint system 720 also incorporatesrestraint bars 815, preferably made of aluminum tubing or extrusions,with the glass-facing surface including a cushion similar to that of thepressing panel 440. The restraint system 720 is also advantageous as itallows the container to accommodate a wide number of glass substraterequirements, ranging from 1 to N, where N represents the design counttotal for a given container.

For instance, in this preferred embodiment, when the cover 710 isinstalled on the main frame and touches the back of the support panel730, and after being affixed to the frame by the clamping members 820,the integrated scissor-like mechanism 810 within the restraint system720 operating from within the underside of the cover is activated andthe “scissors” 810 begin to expand or open up. The scissors 810 willopen up until the restraint bar 815 touches upon the top surface of theglass sheet resting on top of the stack of glass sheets, thereby holdingin or restraining the glass sheets. This provides stability regardlesshow full the container is, since the glass sheets are not free to movearound within the container. This embodiment accommodates the instancewhere there is only one sheet of glass as well as the instance where thecontainer is filled to capacity, i.e. with N glass sheets, such thatthere is no room for more glass sheets to be added. In the formerinstance where there is one or just a few glass sheets, the scissors 810would expand rather wide causing the restraint bar 815 to press upagainst the front surface of the forward-most glass sheet, as shown inFIG. 10. And in the latter instance where there are many glass sheets inthe container, the scissors would not expand as widely before therestraint bar 815 presses up against the front surface of theforward-most glass sheet, as shown in FIG. 9. It should be noted thatone or more scissor mechanisms 810 and one or more restraint bars 815are contemplated by the present invention and would simply depend ondesign choice and effectiveness.

The mechanism utilized to operate the scissor-like mechanism can beapplied automatically by a machine through an appropriate drive system,such as an electric motor or like device, or by a user via a simplemechanical crank or hand wheel for manual operation (not shown). Such amechanism has the ability to set and maintain (i.e. lock) apredetermined amount of restraint force to a single sheet of glass or tothe full capacity of the container or to any intermediate quantities ofglass sheets.

Referring now to FIG. 11, another alternate preferred embodiment of thepresent invention is shown having a container 1100 including a crank orhand wheel 1110 designed onto the cover 1120 for use in operating therestraining system. As shown, the crank 1110 would need manualoperation. It is also contemplated by the present invention that thecrank 1110 can be replaced with an interface for a tool or a robot tooperate the system automatically. Also shown are counter-rotatingright-angle gear boxes 1130 provided on the cover 1120 to translaterotary motion on vertical drive shafts 1140 to rotary motion onhorizontal drive shafts 1141 and permit each side to rotate in oppositedirections. Four torque-limiting devices 1150 on horizontal drive shafts1141 ensure that appropriate restraint force is applied to the glassstack inside the container 1100. Additionally, four locking devices 1160on horizontal drive shafts 1141 secure the restraint after theappropriate force has been applied. Mechanical positioning devices suchas dove-tail linear positioning stages 1170 are shown at four corners ofthe horizontal drive shafts 1141 with lead-screws (not shown) and areprovided as a means of translating the rotary motion of the drive shaft1141 into linear motion of the integrated retaining bars (shown infra inFIG. 13 parallel to the glass) into the front of the glass stack. Theretaining bars are attached to the linear positioning stages 1170 ateach end of the bar preferably in a horizontal orientation.

As shown in FIG. 12, (shown in transparency for illustration purposesonly), these stages 1170 include right-angle gear boxes 1180 for theinterface to the horizontal drive shafts 1141. Also shown in FIG. 12 isanother right-angle gear box 1181 under the crank 1110 which translatesthe rotary motion from the crank 1110 to rotary motion on drive shafts1140 and 1141, respectively. Shaft support and coupling type devices arealso included in the design.

Integrated retaining bar 1190 shown in FIG. 13 can move in and out fromthe inside front surface of the cover 1120 as required by the amount ofglass sheets stacked in the container 1100. The retaining bar 1190preferably incorporates cushioning material as discussed supra inconjunction with other embodiments (not shown). Two retaining bars areshown in FIG. 13 near the top and bottom of the inside of the cover1120. Though two retaining bars 1190 are shown, the present inventioncontemplates the use of one or more retaining bars 1190 as needed fordesired effectiveness. These top and bottom retaining bars 1190preferably operate independently from each other in accordance with thepreferred embodiment of the present invention. As such, adequaterestraint on the glass stack where the glass thickness is not the sameat the top as it is at the bottom, a condition commonly referred to asfanning, is provided. Additionally, torque limiting devices 1150 alloweach end of the retaining bar 1190 to operate independently. Thisresolves instances where the retaining bar 1190 and glass surfaces arenot parallel to each other, which can be caused by fabricationtolerances of the cover and frame, as well as potentially from the glasspacking process itself.

In yet a still further alternate embodiment of the present invention, arestraint system similar to the more or less front-mounted systemdescribed in FIGS. 11-13, can also be mounted on the back of the frame,such as retaining bar pulling system 1410 as shown in FIG. 14. Thesystem includes a gear box 1420, torque limiting devices 1430, leadscrew devices or threaded shafts 1440 and drive shafts 1450 which rotatein the same direction. The pulling system 1410 is connected to theretaining bar (which remains integrated to the cover, not shown in FIG.14) via a detachable interface such as cable 1510 and hook 1520 as shownin FIG. 15 and further allowing for disconnection when there is a needfor removal of the cover. Also shown in FIG. 15 is the attachment pointfor the retaining bar 1530. The back-mounted embodiment incorporatesmany of the nuances of the front-mounted system as described supra.

The cover in the back-mounted embodiment preferably includes a retainingbar retraction mechanism 1600 shown in FIG. 16 to retract the retainingbar 1610 to the inside front surface of the cover thereby facilitatingremoval and installation of the cover preferably including springs 1620,cables 1630, or similar means capable of providing automated retraction.The attachment point 1640 of the retraction mechanism to the retainingbar is shown at the end of a cable 1630 and the attachment point of theback-mounted mechanical system to the retaining bar 1610 is shown at1650 via cable 1510 and hook 1520.

FIG. 17 provides an alternate inside view illustrating theabove-mentioned attachment points 1640 and 1650 of both the retractionmechanism 1600 and the cable 1510 and hook 1520 apparatus to theretaining bar 1610 which is integrated into the cover as depicted.

Advantages to these preferred embodiments of the invention includeenabling one of ordinary skill in the art to apply automated handlingtechniques where necessary and practical, (i.e. where size and weightlimitations are recognized as potential problems for cover installationor removal and/or glass installation or removal), while also allowingfor, in yet another alternate preferred embodiment system, manualoperation which may still always be chosen if desired, in lieu ofautomatic operation.

A key advantage for the invention embodiments described herein is thatthe overall system design provides unrestricted access to the glass,which provides maximum flexibility for unloading the glass and removingthe paper or other interleaving. Another key advantage is the ability toprovide controllable and adjustable glass retention pressure to preventthe movement of glass during transportation.

The embodiments of the present invention described in FIGS. 1 to 17allow for scalability up or down in size of glass sheets, accommodatingdifferent sizes of glass sheets within a defined range represented in ageneration family, and maintaining the basic standards for glassorientation, such as inclined position, landscape orientation of theglass in the container, dust and weather resistant design construction,and the ability to pack as few as one (1) sheet of glass (without theuse of dunnage or mechanical spacers to fill the gap between retainerand glass sheets) to as many as N glass sheets for high efficiencytransportation and storage. The container described herein is reusableand as such, a cost-effective approach to packaging and transportation.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention. Thus it isintended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

1. A container for packaging and transporting one or more glass sheets,comprising: a frame having a pallet with a base; a cover secured to saidpallet such that said one or more glass sheets is sealably coveredtherewith; a support panel and seat provided with cushioning members;and restraining means for controllably and adjustably retaining said oneor more glass sheets with respect to said support panel of said pallet.2. The container according to claim 1, wherein the restraining meansfurther comprises one or more retaining bars moving towards and awayfrom the front of the one or more glass sheets and a mechanical systemfor moving said one or more retaining bars.
 3. The container accordingto claim 2, wherein said restraining means is integrated into saidcover.
 4. The container according to claim 2 wherein said restrainingmeans further includes a pressing panel coupled with said retainingbars.
 5. The container according to claim 4 wherein said mechanicalsystem further includes a plurality of belts and belt restraint devices.6. The container according to claim 3, wherein said restraining meansfurther includes at least one scissor-like mechanical system coupled tosaid one or more retaining bars.
 7. The container according to claim 3,wherein said restraining means further includes a plurality ofmechanical positioning devices coupled to said one or more retainingbars.
 8. The container according to claim 2 wherein said mechanicalsystem is integrated with said frame.
 9. The container according toclaim 8 wherein said mechanical system includes a retaining bar pullingsystem.
 10. The container according to claim 2 wherein the restrainingmeans is operated automatically.
 11. The container according to claim 2wherein the restraining means is operated manually.
 12. The container ofclaim 1 wherein said cover is sealably affixed to the frame via a gasketseal.
 13. The container of claim 4 wherein said pressing panel isremovable.
 14. The container of claim 2 wherein said retaining barsoperate independently from each other.
 15. The container of claim 11wherein said restraining means further comprises vertical posts.
 16. Thecontainer according to claim 1 wherein the frame and cover are made of ametal or other composite material.
 17. The container according to claim1 can accommodate a range of sizes for said one or more glass sheetsizes.
 18. The container according to claim 1, wherein said one or moreglass sheets are stacked with no spacing in between.
 19. The containeraccording to claim 18 wherein non-scratching interleaf materials arepositioned between the glass sheets.
 20. The container according toclaim 19 wherein said interleaf materials further comprise non-adhesiveplastic films attached on either side of each glass sheet.
 21. Thecontainer according to claim 19 wherein a paper sheet is disposedbetween each of said interleaf materials.